fuel injector SUBARU LEGACY 1999 Service Repair Manual

CAUTION:
Never rotate idle adjusting screw. If idle speed
is out of specifications, refer to General On-
board Diagnosis Table under ª2-7 On-Board
Diagnostics II Systemº.
4. Engine Compression
A: MEASUREMENT
1. 2200 cc MODEL
1) After warming-up the engine, turn ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Remove all the spark plugs.
4) Disconnect connectors from fuel injectors.
5) Fully open throttle valve.
6) Check the starter motor for satisfactory perfor-
mance and operation.
7) Hold the compression gauge tight against the
spark plug hole.
CAUTION:
When using a screw-in type compression
gauge, the screw (put into cylinder head spark
plug hole) should be less than 18 mm (0.71 in)
long.
8) Crank the engine by means of the starter motor,
and read the maximum value on the gauge when
the pointer is steady.
G2M0098
9) Perform at least two measurements per
cylinder, and make sure that the values are correct.
Compression (200 Ð 300 rpm and fully open
throttle):
Standard;
1,079 Ð 1,275 kPa (11.0 Ð 13.0 kg/cm
2,
156 Ð 185 psi)
Limit;
883 kPa (9.0 kg/cm
2, 128 psi)
Difference between cylinders;
196 kPa (2.0 kg/cm
2, 28 psi)
4
2-2[W4A1]SERVICE PROCEDURE
4. Engine Compression

CAUTION:
Never rotate idle adjusting screw. If idle speed
is out of specifications, refer to General On-
board Diagnosis Table under ª2-7 On-Board
Diagnostics II Systemº.
4. Engine Compression
A: MEASUREMENT
1. 2200 cc MODEL
1) After warming-up the engine, turn ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Remove all the spark plugs.
4) Disconnect connectors from fuel injectors.
5) Fully open throttle valve.
6) Check the starter motor for satisfactory perfor-
mance and operation.
7) Hold the compression gauge tight against the
spark plug hole.
CAUTION:
When using a screw-in type compression
gauge, the screw (put into cylinder head spark
plug hole) should be less than 18 mm (0.71 in)
long.
8) Crank the engine by means of the starter motor,
and read the maximum value on the gauge when
the pointer is steady.
G2M0098
9) Perform at least two measurements per
cylinder, and make sure that the values are correct.
Compression (200 Ð 300 rpm and fully open
throttle):
Standard;
1,079 Ð 1,275 kPa (11.0 Ð 13.0 kg/cm
2,
156 Ð 185 psi)
Limit;
883 kPa (9.0 kg/cm
2, 128 psi)
Difference between cylinders;
196 kPa (2.0 kg/cm
2, 28 psi)
4
2-2[W4A1]SERVICE PROCEDURE
4. Engine Compression

2. 2500 cc MODEL
CAUTION:
After warming-up, engine becomes very hot.
Be careful not to burn yourself during mea-
surement.
1) After warming-up the engine, turn ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Remove all the spark plugs. [W3B0].>
4) Disconnect connectors from fuel injectors.
5) Fully open throttle valve.
6) Check the starter motor for satisfactory perfor-
mance and operation.
7) Hold the compression gauge tight against the
spark plug hole.
CAUTION:
When using a screw-in type compression
gauge, the screw (put into cylinder head spark
plug hole) should be less than 18 mm (0.71 in)
long.
8) Crank the engine by means of the starter motor,
and read the maximum value on the gauge when
the pointer is steady.
B2M0752A
9) Perform at least two measurements per
cylinder, and make sure that the values are correct.
Compression (350 rpm and fully open
throttle):
Standard;
1,216 kPa (12.4 kg/cm
2, 176 psi)
Limit;
941 kPa (9.6 kg/cm
2, 137 psi)
Difference between cylinders;
49 kPa (0.5 kg/cm
2, 7 psi), or less
5. Intake Manifold Vacuum
A: MEASUREMENT
1) Warm-up the engine.
2) Disconnect the brake vacuum hose and install
the vacuum gauge to the hose fitting on the mani-
fold.
3) Keep the engine at the idle speed and read the
vacuum gauge indication.
By observing the gauge needle movement, the
internal condition of the engine can be diagnosed
as described below.
H2M1601
Vacuum pressure (at idling, A/C ªOFFº):
Less than þ60.0 kPa (þ450 mmHg, þ17.72
inHg)
5
[W5A0]2-2SERVICE PROCEDURE
5. Intake Manifold Vacuum

2. 2500 cc MODEL
CAUTION:
After warming-up, engine becomes very hot.
Be careful not to burn yourself during mea-
surement.
1) After warming-up the engine, turn ignition
switch to OFF.
2) Make sure that the battery is fully charged.
3) Remove all the spark plugs. [W3B0].>
4) Disconnect connectors from fuel injectors.
5) Fully open throttle valve.
6) Check the starter motor for satisfactory perfor-
mance and operation.
7) Hold the compression gauge tight against the
spark plug hole.
CAUTION:
When using a screw-in type compression
gauge, the screw (put into cylinder head spark
plug hole) should be less than 18 mm (0.71 in)
long.
8) Crank the engine by means of the starter motor,
and read the maximum value on the gauge when
the pointer is steady.
B2M0752A
9) Perform at least two measurements per
cylinder, and make sure that the values are correct.
Compression (350 rpm and fully open
throttle):
Standard;
1,216 kPa (12.4 kg/cm
2, 176 psi)
Limit;
941 kPa (9.6 kg/cm
2, 137 psi)
Difference between cylinders;
49 kPa (0.5 kg/cm
2, 7 psi), or less
5. Intake Manifold Vacuum
A: MEASUREMENT
1) Warm-up the engine.
2) Disconnect the brake vacuum hose and install
the vacuum gauge to the hose fitting on the mani-
fold.
3) Keep the engine at the idle speed and read the
vacuum gauge indication.
By observing the gauge needle movement, the
internal condition of the engine can be diagnosed
as described below.
H2M1601
Vacuum pressure (at idling, A/C ªOFFº):
Less than þ60.0 kPa (þ450 mmHg, þ17.72
inHg)
5
[W5A0]2-2SERVICE PROCEDURE
5. Intake Manifold Vacuum

2. Engine Noise
Type of sound Condition Possible cause
Regular clicking soundSound increases as engine
speed increases.IValve mechanism is defective.
IIncorrect valve clearance
IWorn valve rocker
IWorn camshaft
IBroken valve spring
Heavy and dull clankOil pressure is low.IWorn crankshaft main bearing
IWorn connecting rod bearing (big end)
Oil pressure is normal.ILoose flywheel mounting bolts
IDamaged engine mounting
High-pitched clank
(Spark knock)Sound is noticeable when
accelerating with an overload.IIgnition timing advanced
IAccumulation of carbon inside combustion chamber
IWrong spark plug
IImproper gasoline
Clank when engine speed is
medium (1,000 to 2,000 rpm)Sound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*)IWorn crankshaft main bearing
IWorn bearing at crankshaft end of connecting rod
Knocking sound when engine
is operating under idling speed
and engine is warmSound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*)IWorn cylinder liner and piston ring
IBroken or stuck piston ring
IWorn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is dis-
connected in turn. (NOTE*)IUnusually worn valve lifter
IWorn cam gear
IWorn camshaft journal bore in crankcase
Squeaky sound ÐIInsufficient generator lubrication
Rubbing sound ÐIDefective generator brush and rotor contact
Gear scream when starting
engineÐIDefective ignition starter switch
IWorn gear and starter pinion
Sound like polishing glass with
a dry clothÐILoose drive belt
IDefective engine coolant pump shaft
Hissing sound ÐILoss of compression
IAir leakage in air intake system, hoses, connections or
manifolds
Timing belt noise ÐILoose timing belt
IBelt contacting case/adjacent part
Valve tappet noise ÐIIncorrect valve clearance
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is
stored in ECM memory.
Therefore, carry out the CLEAR MEMORY MODE and INSPECTION MODE after con-
necting fuel injector connector.
78
2-3a[K200]DIAGNOSTICS
2. Engine Noise

2. Engine Noise
If noise still exists, conduct diagnostics procedures
in accordance with the following table.CAUTION:
Do not disconnect spark plug cord while
engine is running.
Type of sound Condition Possible cause
Regular clicking soundSound increases as engine
speed increases.Valve mechanism is defective.
IIncorrect valve clearance
IWorn camshaft
IBroken valve spring
Heavy and dull clankOil pressure is low.IWorn crankshaft main bearing
IWorn connecting rod bearing (big end)
Oil pressure is normal.ILoose flywheel mounting bolts
IDamaged engine mounting
High-pitched clank
(Spark knock)Sound is noticeable when
accelerating with an overload.IIgnition timing advanced
IAccumulation of carbon inside combustion chamber
IWrong spark plug
IImproper gasoline
Clank when engine speed is
medium (1,000 to 2,000 rpm).Sound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*)IWorn crankshaft main bearing
IWorn bearing at crankshaft end of connecting rod
Knocking sound when engine
is operating under idling speed
and engine is warm.Sound is reduced when fuel
injector connector of noisy cyl-
inder is disconnected.
(NOTE*)IWorn cylinder liner and piston ring
IBroken or stuck piston ring
IWorn piston pin and hole at piston end of connecting rod
Sound is not reduced if each
fuel injector connector is dis-
connected in turn.
(NOTE*)IUnusually worn valve lifter
IWorn camshaft journal bore in crankcase
Squeaky sound ÐIInsufficient generator lubrication
Rubbing sound ÐIDefective generator brush and rotor contact
Gear scream when starting
engineÐIDefective ignition starter switch
IWorn gear and starter pinion
Sound like polishing glass with
a dry clothÐILoose drive belt
IDefective engine coolant pump shaft
Hissing sound ÐILoss of compression
IAir leakage in air intake system, hoses, connections or
manifolds
Timing belt noise ÐILoose timing belt
IBelt contacting case/adjacent part
Valve tappet noise ÐIIncorrect valve clearance
NOTE*:
When disconnecting fuel injector connector, Malfunction Indicator Light (CHECK ENGINE light) illuminates and trouble code is
stored in ECM memory.
Therefore, carry out the CLEAR MEMORY MODE and INSPECTION MODE after connecting fuel injector connector. [T6A0].>
76
2-3b[K200]DIAGNOSTICS
2. Engine Noise

1. Intake Manifold
A: 2200 cc CALIFORNIA SPEC. VEHICLES
B2M2276A
(1) Intake manifold gasket RH
(2) Fuel injector cap
(3) Insulator A
(4) Insulator B
(5) Fuel injector
(6) O-ring B
(7) O-ring A
(8) Fuel pipe
(9) Nipple (AT vehicles)(10) Plug
(11) PCV valve
(12) Purge control solenoid valve
(13) Nipple
(14) Intake manifold
(15) Intake manifold gasket LH
(16) Fuel pipe protector LH (LHD
model)(17) Fuel pipe protector RH (RHD
model)
Tightening torque: N´m (kg-m, ft-lb)
T1:
16±1.5 (1.6±0.15, 11.6±1.1)
T2:23±3 (2.3±0.3, 16.6±2.2)
T3:25±2 (2.5±0.2, 18.1±1.4)
T4:3.4±0.5 (0.35±0.05, 2.5±0.4)
2
2-7[C1A0]COMPONENT PARTS
1. Intake Manifold

(1) Intake manifold gasket LH
(2) Intake manifold gasket RH
(3) Fuel injector pipe
(4) O-ring A
(5) O-ring B
(6) Fuel injector
(7) Insulator
(8) Fuel injector cap
(9) Nipple (AT vehicles)
(10) Plug
(11) PCV valve
(12) Purge control solenoid valve(13) Nipple
(14) Pressure sensor
(15) Pressure sources switching sole-
noid valve
(16) Vacuum hose A
(17) Vacuum hose B
(18) Vacuum hose C
(19) Bracket (Except Canada spec.
vehicles)
(20) Bracket (For Canada spec.
vehicles)
(21) Intake manifold(22) Fuel pipe protector LH (LHD
model)
(23) Fuel pipe protector RH (RHD
model)
Tightening torque: N´m (kg-m, ft-lb)
T1:
4.9±0.5 (0.5±0.05, 3.6±0.4)
T2:23±3 (2.3±0.3, 16.6±2.2)
T3:25±2 (2.5±0.2, 18.1±1.4)
T4:3.4±0.5 (0.35±0.05, 2.5±0.4)
T5:15.7±1.5 (1.6±0.15, 11.6±1.1)
5
[C1B0]2-7COMPONENT PARTS
1. Intake Manifold

(1) Intake manifold gasket LH
(2) Intake manifold gasket RH
(3) Fuel injector pipe insulator
(4) Fuel injector pipe
(5) O-ring A
(6) O-ring B
(7) Fuel injector
(8) Insulator
(9) Fuel injector cap
(10) Plate
(11) Sealing
(12) Gasket
(13) Engine coolant hose B
(14) Air by-pass hose
(15) Idle air control solenoid valve
(16) Engine coolant hose A
(17) Nipple (AT vehicles)
(18) Plug
(19) PCV valve(20) Purge control solenoid valve
(21) Nipple
(22) BPT
(23) BPT holder bracket
(24) Back pressure hose
(25) EGR vacuum hose A
(26) EGR vacuum pipe
(27) EGR vacuum hose C
(28) EGR valve
(29) Gasket
(30) EGR vacuum hose B
(31) EGR solenoid valve
(32) EGR pipe
(33) Pressure sensor
(34) Pressure sources switching sole-
noid valve
(35) Vacuum hose A
(36) Vacuum hose B
(37) Vacuum hose C(38) Bracket (Except Canada spec.
vehicles)
(39) Bracket (For Canada spec.
vehicles)
(40) Collar
(41) Intake manifold
Tightening torque: N´m (kg-m, ft-lb)
T1:
3.4±0.5 (0.35±0.05, 2.5±0.4)
T2:4.9±0.5 (0.5±0.05, 3.6±0.4)
T3:6.4±0.5 (0.65±0.05, 4.7±0.4)
T4:16±1.5 (1.6±0.15, 11.6±1.1)
T5:19±1.5 (1.9±0.15, 13.7±1.1)
T6:19±2 (1.9±0.2, 13.7±1.4)
T7:23±3 (2.3±0.3, 16.6±2.2)
T8:25±2 (2.5±0.2, 18.1±1.4)
T9:34±2 (3.5±0.2, 25.3±1.4)
7
[C1C0]2-7COMPONENT PARTS
1. Intake Manifold

28) Remove bolts which hold intake manifold onto
cylinder heads.
S2M0091
29) Remove intake manifold.
B2M0160
B: DISASSEMBLY
1. 2200 cc CALIFORNIA SPEC. VEHICLES
1) Disconnect engine ground terminal from intake
manifold.
B2M2779
2) Disconnect connector from ignition coil and
ignitor assembly.3) Remove ignition coil and ignitor assembly.
B2M2345
4) Disconnect connectors from throttle position
sensor (A), idle air control solenoid valve (B) and
intake manifold pressure sensor (C).
5) Disconnect air by-pass hose (D) from idle air
control solenoid valve.
B2M2346A
6) Remove throttle body.
B2M2300
7) Disconnect connectors from fuel injectors, and
purge control solenoid valve.
37
[W4B1]2-7SERVICE PROCEDURE
4. Intake Manifold